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1. 3 step guide to rolled ring forgings
Rolled ring forgings process is used to make ring shaped objects with less than an inch in
diameter to cylindrical shapes that have diameters measuring hundreds of inches. A wide range
of industrial products for nuclear reactors, pressure vessels, off-road equipment, bearings and
gears weighing just a few pounds to hundreds of metric tonnes are made using this process.The
process can be used for most metals used in high temperature applications.
Understanding the process
The rolling ring process is done on rolling mills where a metal that are heated above the
recrystallization temperature are rolled till a ring of desired wall thickness is achieved. The metal
is first shaped into a donut like structure and then placed on an idler roller. The idler roller
continuously presses against another roller called the drive roller. The metal is kept in place
using axial rollers. As the idler roller presses against the drive, the thickness of the metal
decreases in an uniform manner due to high speed rotation. The process continues till a seamless
ring of desired thickness is achieved. Rolled ring forgings can be of varying of diameters as
well.
Metal specifications
Commonly used industrial grade metals for making rings are Carbon low alloy, stainless steel,
aluminium and titanium. Each of these metals produces rings with varying specifications. While
the inner diameter can range from 10 inches, the maximum outer diameter normally does not
exceed 120 inches for aluminium and titanium while the other two metals allow making slightly
larger rings with outer diameters measuring 128 inches. A major difference in application is that
titanium cannot be used to make tall rings. The maximum height of forgings that can be made of
titanium is 10 inches. Carbon also stands out as it can be used for making rings that weigh as
much as 6,500 lb, nearly the max weight of ring that can be made of stainless steel which is the
most commonly used alloy for rings.
Advantages
Rolled rings forgings are strong as they do not have welds and are single piece design. Rolling is
a cost saving compared to other processes like machined bar as it does not produce wastage and
requires considerably less machining to make rings. Rings of large sizes can be made and the
grade flexibility is also higher compared to other processes. The rings have consistent
metallurgical properties and reduce dependence on labour for inspection and quality control.